Flexible Coolant Pouch Assembly for Submerged Battery Thermal Control
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Solution Overview
Problem
Existing temperature regulating systems for high storage rechargeable batteries, such as Lithium-ion batteries, face challenges in extreme temperature conditions, leading to reduced operational performance and increased risk of fires due to complex and costly structures that are difficult to manufacture and scale.
Innovation Solution
A flexible pouch-based coolant reservoir assembly system that submerges battery cells in a dielectric liquid, providing consistent temperature control and flame suppression, while minimizing tooling investments and enabling scalable production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex plastic or metal structures are used to contain submerged batteries and liquid coolant, then temperature regulation effectiveness is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent employs a flexible pouch as the containment structure for both the battery and coolant. This thin-film approach replaces complex rigid plastic or metal structures, achieving effective temperature regulation through direct contact between the battery and coolant while significantly reducing manufacturing cost and structural complexity. The flexible pouch conforms to the battery shape, ensuring optimal thermal contact.
2Reliability
If complex plastic or metal structures are used to contain submerged batteries and liquid coolant, then temperature regulation effectiveness is improved, but ease of manufacture and scalability worsen
Solution Approach 1:
The flexible pouch can be easily manufactured using standard lamination and sealing techniques for multi-layer films. The pouch is produced as a flat laminate structure that is then formed and sealed, allowing for simple assembly processes and easy scalability. This approach eliminates the need for complex mold tooling required for rigid plastic or metal structures.
Solution Approach 2:
The containment system is segmented into distinct functional layers within the pouch structure, with each layer performing a specific function (coolant containment, thermal management, protection). This modular layering simplifies manufacturing by allowing each layer to be produced and quality-checked independently before final assembly.
3Reliability
If expensive tooling investment is made for complex structures, then temperature regulation performance is improved, but cost-effectiveness deteriorates
Solution Approach 1:
The flexible pouch containment structure eliminates the need for expensive mold tooling required for rigid plastic or metal structures. The pouch is manufactured using standard lamination and sealing processes for multi-layer films, which are far less capital-intensive. This dramatically improves cost-effectiveness while maintaining effective temperature regulation performance through direct coolant-battery contact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The flexible pouch system effectively regulates battery temperatures, reduces the risk of fires, and is cost-effective and scalable, improving battery performance and safety.
Implementation Method 1
liquid coolant to both cool and heat such batteries as temperatures and loads require
Implementation Method 2
submerging battery cells in a dielectric liquid... flame suppression
Data Source
AI summary
A battery coolant reservoir assembly can include an exterior structure having an interior surface defining an interior space, a flexible coolant retaining pouch coupled to a manifold, and a battery module disposed within the coolant retaining pouch. The coolant retaining pouch can be disposed in the interior space of the exterior structure. Related systems and methods are also provided.